hi,
i have a 97 ranger that has all metal body panels; some of which are in need of a new paint job. This got me thinking, what if i were to replace these heavy all with light, home made body panels. These would be made by vacuforming negatives and then positives, then reinforcing them with a spray type foam insulation. and epoxy on metal brackets (before the foam).
i could even go and make wheel skirts built in.
i mainly drive in town so weight is very important.
Theoretical Procedure:
-Setup
1. make a vaccum platform out of duct board (the stuff department stores use to hang small merchendise on hooks on) and add thin board in the center to cover holes.
2. make vertical rails to align plastic onto the form
3. make a kiln out of scrap bricks i have
4. have a large sheet of stainless steel between heating source and plastic chamber to distribute heat.
5. insert a metal bladed fan between bricks in the back of the kiln for convection current
6. use 2 or more shopvacs in platform
-Procedure
1. Remove body panel from vehicle
2. place body panel on vaccum platform and use sand to make it sturdy and prevent plastic from going under body panel
3. apply some kind of lubercant to body panel. ive read petrolium jelly might work.
4. heat up plastic sheet with a frame until the center droops x inches
5. start up shopvacs
6. take plastic out of kiln
7. quickly align up vertical poles and slide plastic down onto the form
8. wait until plastic cools but is still pliable and remove form body panel
9. sand plastic and fill in any imperfections
10. drill small holes in the peaks of the plastic, for air to come out.
11. repeat steps 2-9 to make positive replica
12. make mounting brackets out of scrap metal to match those on origional and attach with plastic epoxy
13. use spray insulation foam on underside of new body panel for strength (about an inch or two in thickness is all that is needed)
14. test for a fit on vehicle and scrape to remove foam where needed
15. prep for painting as stated in the link below, and proceed to paint.
painting plastic body panels and different types
Background on vacuforming
More info on body painting